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Zazu Puppet
University Module
Final Major Project
Material & Techniques used
Fiberglass Mould making and Casting, Clay Sculpting
This project was created as my Final Major Project for my Model Design degree and focused on the construction of a theatrical Zazu puppet inspired by The Lion King West End production. I chose Zazu because of the unique combination of sculpture, costume, and puppetry used to bring the character to life on stage.
The project began with sculpting the head in buff clay before producing a silicone and fibreglass matrix mould. The final head was cast in fibreglass to create a lightweight yet durable structure suitable for performance. The body was primarily made from foam and parachute silk, allowing for fluid movement and a lightweight finish. I also engineered a moving beak mechanism using a bicycle brake cable system, enabling the puppet to open and close expressively during operation.
This project allowed me to develop my skills in sculpting, mould making, fibreglass casting, and mechanical problem-solving, while further strengthening my interest in theatrical prop and puppet design.
